Method and apparatus for rewinding loose end portions of loosely wound spools

ABSTRACT

Coreless spools, alternately wound on two spindle mounted mandrels from a continuous web supply of thin sheet material, are jet propulsively ejected from the mandrels by pressurized fluid conducted thereto. Loose end portions of the completed spools are rewrapped about the spool body by bridging a gap between two conveyors and two air curtains.

United States Patent 1191 Dowd, Jr.

1451 Aug. 20, 1974 METHOD AND APPARATUS FOR REWINDING LOOSE END PORTIONSOF LOOSELY'WOUND SPOOLS [75] Inventor: Daniel J. Dowd, Jr., CliftonForge,

[73] Assignee: Westvaco Corporation, New York,

22 Filed: Dec 12,1973

21 Appl.No.:424,093

Related U.S. Application Data [62] Division of Ser. No. 216,629, Jan.10, 1972, Pat. No.

[52] U.S. Cl. 93/84 FF, 93/81 R, 93/94 R [51] Int. Cl. B3lc 1/08 [58]Field of Search 271/195; 93/84 FF, 84 R, 93/94 R, 18, 77 R, 81 R, 81 MT,1 R

[56] References Cited UNITED STATES PATENTS 3,105,421 10/1963 Petri93/81 MT 3,451,195 6/1969 Roth et a1. 93/84 FF 3,463,482 8/1969 Baron eta1 3,513,625 5/1970 Eller et a1 93/84 FF Primary Examiner-Roy LakeAssistant Examiner-James F. Coan Attorney, Agent, or FirmW. AllenMarcontell;

Richard L.Schma1z ['5 7] ABSTRACT Coreless spools, alternately wound ontwo spindle mounted mandrels from a continuous web supply of thin sheetmaterial, are jet propulsively ejected from the mandrels by pressurizedfluid conducted thereto. Loose end portions of the completed spools arerewrapped about the spool body by bridging a gap between two conveyorsand two air curtains.

5 Claims, 6 Drawing Figures pmm n msamaz sum cm 3' FIG. 5d

METHOD AND APPARATUS FOR REWINDING LOOSE END PORTIONS OF LOOSELY WOUNDSPOOLS This is a division of application Ser. No. 216,629, filed Jan.10, 1972, now US. Pat. No. 3,802,639.

BACKGROUND OF THE INVENTION Although such fluid assistance for startingand finish-.

ing a spool winding cycle as taught by Link is of value, manual removalof the finished spool is still necessary. Accordingly, if greaterproduction rates from such spool winding devices are to be realized,such manual functions in the operation must be eliminated.

SUMMARY OF THE INVENTION An objective of the present invention,therefore, is to provide a method and apparatus for rapid and positiveejection of a completed spool from the winding mandrel.

Another object of the invention is to teach a material flow strategy toa plurality of winding mandrels.

Another object of the invention is to teach a method and apparatus forrewrapping loose ends of ejected spools.

These and other objects of the invention may be accomplished by drivingthe web flow path into an oscillating deflector for chuting the web toone of a plurality of winding mandrels.

The leading edge of the web is drawn into a converging nip between thereceiving mandrel and surface friction drive belts therefor. A vacuumbias applied to the surface of the mandrel serves to adhere the webleading edge thereto until the first full wrap is complete and assistswith tight, smooth layering for wraps applied thereafter.

When the desired length of web designated to form a spool has passed,the web is transversely severed above the deflector which indexes to thenext chute position for directing the new leading edge into the nextwinding apparatus.

Meanwhile, tail winding of the previous spool is completed.

Sequentially thereafter, the spool wrapped mandrel disengages from thesurface drive belts for acceleration to a greater rotational velocity.The mandrel surface vacuum is then replaced with a pressurized fluidflow which expands the spool from the mandrel surface in such a manneras to either impulsively or reactively propel the spool over the mandrelend and onto a receiving conveyor. This receiving conveyor delivers thespool across an air curtain which presses any free end portions againstthe conveyor surface plane to be carried into a gap between the deliveryend of the receiving conveyor and the receiving end of a deliveryconveyor. The gap dimensions, however, are insufficient to accommodatethe main spool body which bridges the gap in transfer from saidreceiving to said delivery conveyor. The transition causes the free endportion to be drawn from the gap and under the spool main portion.

A subsequent air curtain may be used to blow any remaining free endportion of the spool up and over said main body portion.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic representationof the present invention showing the spool winding operation on one oftwo mandrels.

FIG. 2 is a schematic representation of the present invention showingthe spool winding operation on the other of the two mandrels with thecutting mechanism engaged.

FIG. 3a is a side elevation of the deflector apparatus.

FIG. 3b is an end elevational of the deflector apparatus.

FIG. 4 is an elevational detail of the mandrel, mandrel drive, ejectedspool braking mechanism, and the receiving conveyor station shown inpartial section.

FIG. 5a is a detail of the mandrel and drive mechanism during the spoolwinding process.

FIG. 5b shows the next sequential step from FIG. 5a in preparation of awound spool for ejection.

FIG. 50 shows the pressurized expansion of a spool immediatelyantecedent to ejection.

FIG. 5d shows the initial ejective movement of a spool from the mandrel.

FIG. 6a schematically shows the spool receiving and delivery conveyorsfor rewinding loose end portions thereof.

FIGS. 6b and 6c sequentially show a spool bridging the gap between thetwo conveyor sections to illustrate a critical portion of the rewrappingprocess.

DESCRIPTION OF THE PREFERRED EMBODIMENT 'rial of indefinite length isdrawn from the active supply roll 20 and turned over one of bars 22 intothe nip of the web pulling section.

This pulling section comprises pulling drums 23 which are drivencylinders having a traction belt 25 wrapped partially thereabout. Forgreater area distribution of the pullingsection nip pressure, theportion of the belts 25 in actual contact with the web W is increased byturning the belts over idler rolls 24.

Since the web W path through the pulling section is vertical, supplyrolls 20 and 21 may be positioned on either side thereof. Accordinglywhen the web material from one roll is exhausted, supply from areserveroll 21 may be started immediately with minimum time loss.

Upon emerging from the pulling section nip, web W is passed betweencooperative cutting elements and 82 held at the open position anddeflected by the left face 31 of deflector 30 into the nip betweenwinding mandrel 40 and winding belts 51.

Deflector 30, as further shown in FIGS.'3a and 3b is an elongated,hollow triangular body that is offset positioned from the axis ofjournals 33. Position control of the deflector is provided by means ofan eccentric 34 driven connecting rod 35. Such position controlcomprises a small angle oscillatory movement of the deflector apex 39from the position shown in FIG. 1 on the right side of the web path tothe position shown in FIG. 2 on the left side of the web path.

Since, in many cases, the web W product comprises extremely thinmaterial such as crepe or tissue paper, means are provided by thedeflector 30 to prevent undesirable wrinkling and folding of the web asit turns from the straight line path out of the pulling section. Suchmeans provided by the present invention comprises a plurality of lowvelocity air jets 37 emanating from the deflector body at a shallowangle from the plane of the deflector face 31. Moreover the axes 37a andjets 37 are respectively disposed in a radial array of planes emanatingfrom axis 38 which is transverse of the web path W and remote from thedeflector apex ridge 39. This radial or fanlike array of axes 37aprovides a subtle but effective transverse and longitudinal smoothing ofthe web plane as it enters the nips between mandrel 40 and winding belts51.

Air supply to deflector 30 hollow interior is conventionally providedthrough a flexible conduit 36 from a suitable pressurized source. Ofcourse, the jets 37 are provided on both faces 31 and 32 of thedeflector 30.

At this point in the machine cycle, mandrel 40 is internally evacuatedcausing an atmospheric draft radially inward through perforations 47(FIG. 4) in the outer mandrel wall as will be described in greaterdetail relative to FIGS. 4 and 5.

As the nips between mandrel 40 and belts 51 press or wipe the web W intointimate contact with the mandrel 40 outer surface, the atmosphericpressure differential across the web thickness adheres the leading edgethereof to the mandrel surface for completion of the first full wrapafter emerging from the nip between the mandrel and the belts 51.Thereafter, successive wraps of a continuous web length are woundthereon to complete a coreless spool.

Rotational force is provided to the mandrel 40 by surface friction drivefrom the belts 51 which, in turn, are driven by one of the turning rolls50 and 52.

The length of web W wound upon the mandrel may be determined by any ofseveral well known techniques including a gear mechanism or a timer.Although the details of a suitable drive mechanism for the web cuttingmechanism shown are not illustrated, it should be understood that manysuch mechanisms are known to the prior art. Depending on the degree ofprecision desired for the cut length of web W, the rotational positionof drum 81 may or may not be positively coordimated with the rotationalposition of cam 85. If the web W cut length may fluctuate within atolerance defined by the circumferential arc of knife edge 80, thecontinuously rotating drum 81 may be free of any coordinating mechanismwith cam 85. The particular technique selected for description herewith,however, is to cyclically coordinate, by means of chain drives, forexample, the angular position of rotating knife drum 81 with that of camdetents 87. By making the speed of traction belts independently variableof the cutting unit rotational speed, the desired length of .web W toform a spool may be determined by the web W velocity.

When the desired length of web W has passed cam 85 is rotated so thatone of the detents 87 thereon aligns with the bell crank 83 follower 84.Spring 86 provides the bias to urge the follower 84 into continuingcontact with the surface of cam 85.

When the follower 84 drops into a detent 87, the bell crank 83 rotatesthe few degrees necessary to bring the anvil 82 into cutting position.When the rotating drum 81 mounted knife edge 80, traveling at a greatersurface speed than the web W, reaches complimentary alignment with theanvil 82, the web W is sheared therebetween.

To prevent the leading edge of web W following a cut from momentarilyadhering to the anvil 82, drum 81 is sheathed with a resilient foammaterial 88, the circumferential surface thereof radially projectingslightly beyond the edge of knife 80. At the moment of cut, the portionof the foam immediately behind the blade presses the web leading edgeagainst the upper surface of anvil 82 for a frictional grip on saidleading edge to pull it off the anvil 82.

The remaining rotating surface elements of sheath 88 sustain touchingcontact with the web W as it passes thereby lending a positive controlassist to the web path.

The rotational speed of cam also provides a convenient timing referencefor coordinating the cyclic activity of the deflector 30, mandrels 40and 60, the several drive mechanisms and solenoid actuated fluid controlvalves as to be subsequently described. Accord ingly, a multiple lobecam shaft 65 is driven by a timing chain 66 from the drive shaft for cam85 to selectively make and break electrical contacts 67 for eachelectrically actuated control mechanism appropriate for the functionshereinafter described.

After completely winding the tail of a cut length of web W, windingbelts 51 and roller 52 are rotated about the axis of roller 50 todisengage the belts 51 from the wound spool of web W about mandrel 40.If desired, the machine may be designed so that mandrel 40 is displacedin an opposite direction away from the winding belts 51 for completedisengagement therebetween. At this point, the coreless spool of web Wwrapped about mandrel 40 is ejected therefrom in a manner to besubsequently described in detail.

Meanwhile, deflector 30 has been rotated by eccentric 34 mountedconnecting rod 35 from the position shown in FIG. 1 to that of FIG. 2 tochute the new leading edge of web W into the nip between winding mandrel60 and belts 71. The following events pursuant to winding anothercoreless spool of web material are the same as previously describedrelative to mandrel 40.

When the web spool C (FIG. 6a) ejects from the end of mandrel 40, thespeed thereof is first retarded by a breaking section comprisingconverging belts 90 driven by drums 91 over idlers 92 (FIG. 4). Here thespool is flattened to an oval and controllably placed on a receivingconveyor section comprising a multiplicity of spaced belts 101.

Upon emerging from the braking section (FIG. 6a), the tails T of thespools C are uncontrolled and are likely to be lifted free and partiallyunwound from the spool body. To neatly rewrap the tails T onto the spoolbody C, the receiving and delivery conveyor sections 100 and 105,respectively, are provided with air curtains from upper and lowermanifolds 103 and 104 extending transversely across respective conveyorsections. If the tail has come free from the spool body underside asshown by T in FIG. 6a, the tail T is blown by the air curtain from uppermanifold 103 into the crevice 102 between the down stream end ofreceiving conveyor 100 and the upstream end of delivery conveyor 105.Since the radii of turning drums 106 and 107 are critically sized, as isthe width of crevice 102, the spool body C does not follow the tail Tinto the crevice but is merely passed tangentially between the drums 106and 107 across the crevice as illustrated by FIGS. 6b and 6c.Consequently, the free tail T is wrapped under the spool body C In theextreme case, where a free tail T yet remains behind a spool C afterbridging the crevice 102, the air curtain from lower manifold 104' blowssame up and around to the top side of the spool C as shown in FIG. 6arelative to spool C and tail T Accordingly, after passing theaforedescribed tail control section, the tails of such spools layentirely in juxtaposition with the body and in immediate condition forfinal packaging.

Turning next to the internal details of the winding mandrels and themechanics of coreless spool ejection, reference is first made to FIG. 4where the mandrel 40 is shown as a closed, hollow cylinder rotationallymounted on a hollow spindle 41.

One end of the spindle 41 is rigidly secured to a swing arm 42 journaledabout a bearing shaft 53. Conduit 45 is connected, alternatively, topositive and negative (vacuum) fluid pressure sources. Fluidcommunication between conduit 45 and apertures 47 through the shell ofmandrel 40 is allowed via apertures 46 through the shell of spindle 41.

Integral with the swing arm 42 but opposite of the shaft 53 axis fromthe spindle 41 is a cam follower portion 43. The cam 44, in cooperationwith the follower portion 43, is functionally effective to swing themandrel 40 from the winding position of FIG. 1 to the ejection positionof FIG. 2.

In the case of winding belt unit 50, 51 and 52, drum 50 enjoys a fixedaxis about shaft 53 but idler drum 52 oscillates between winding andejection positions. Winding unit 70, 71 and 72, on the other hand enjoysfixed axes for both drums 70 and 72. This distinction, however, is amere designers choice and is not critical to the invention.Nevertheless, for power transmission convenience, drums 50 and 70 shouldbe mounted on fixed axes and driven through a suitable, variable speedtransmission 56. 'In the FIG. 4 embodiment, power is delivered from theinput gear 55, through the transmission 56 and to the drum 50 via belt57.

Experience with the present invention has found the variable speedtransmission 56 extremely useful due to subtle distinctions in windingcharacteristics between different web materials. Even color differencesbetween two, otherwise identical, webs of paper will require differentwinding speeds.

Although the web W winding drive is delivered by belts 51, mandrel 40 isalso independently driven from a suitable, selectively engageablesource, not shown, which delivers power to a transfer reduction sheave54, also mounted on shaft 53, via an input 54b and output 540.

As indicated above, the shell of mandrel 40 is perforated by amultiplicity of apertures 47 drilled therethrough at an angle ofapproximately with and in radial planes of the mandrel axis.

The exact number, angle, and distribution pattern of apertures 47optimum for a given core diameter and weight of particular wound webmaterial are all variable parameters that are dependent upon thepressure and delivery characteristics of a working fluid source and uponthe mechanical characteristics of the particular web material.

In a particular example, however, with a 2.75 inch OD and 20% inch longmandrel provided with 36, 3/32" diameter apertures 47, drilled at a 20angle with the mandrel axis in radial planes, and uniformly distributedaround the mandrel circumference in 8 symetrically offset rows, spoolswound from 20 inch wide and inch long webs of 0.002 caliper crepe paperwere quickly and neatly ejected without axial or telescopic expansionwith an 18 psi source of air pressure.

As described above relative to the winding operation, conduit 45 isconnected to the vacuum source for the mandrel to receive the leadingedge of the web W. This vacuum connection is continued throughout thewinding process, FIG. 5a, and immediately after the wrapped mandrel hasdisengaged from the winding belts 51. When such disengagement iscomplete, power is delivered to the mandrel independent drive train 54to rotationally accelerate the mandrel and wound spool C, the effect ofwhich is to complete the tail wrap and draw the trailing edge T thereofnext to the spool surface C as illustrated by FIG. 5b. Since the web ispermeable, in the case of crepe" or tissue paper, the slight pressuredifferential attraction remaining through a multiplicity of wraps issufficient to adhere the tail T against the cylindrical surface.

' With the independent mandrel drive still engaged, conduit 45 isswitched from the vacuum source to a pressure source causing an airblast from mandrel apertures 47 to expand and distort the cylindricalconfiguration of spool C to that exageratedly shown by FIG. 50.

High speed photographs have shown that under the aforedescribedconditions, the wound spool assumes a bulb shape at the discharge end ofthe mandrel as evidence that the leading axial end L of the spool C isretaining a close circumferential proximity to the mandrel surface andthe air discharged from the apertures 47 is forming a pressure chamberwithin the region B. This circumstance dictates a fluid flow bias in thereverse direction F (relative to the air discharge direction fromapertures 47 and the consequent movement of spool C). Consequently,spool C is, at least partially, reactively propelled from the mandrel 40by the fluid mass discharge in the direction F as shown by FIG. 5d justas any jet powered vehicle.

Although detailed theoretical and laboratory analysis may reveal thatthe cylinder C is also propelled impulsively to some degree, for thepurpose of this disclosure and the claims appended hereto, thephenomena, whether impulsive, reactive or a combination of the two, willbe characterized as reactive propulsion.

It is to be understood that the foregoing description is of a preferredembodiment and that the invention is not to be limited by descriptionsof incidentally disclosed machine elements and power transmissionarrangement. Therefore, changes may be made in the described preferredembodiment without departing from the scope of the invention defined inthe following claims.

I claim:

1. Apparatus for rewinding loose end portions of loosely wound spools ofthin sheet material, said apparatus comprising:

first and second planar conveyance means disposed end to end forconveying loosely wound spools of thin sheet material along asubstantially continuous transfer plane in a first direction, thewinding axis of said spools being substantially transverse to said firstdirection, said first and second conveyance means being separated by adistance at least sufficient to receive a single ply of said sheetmaterial but to be bridged by said spools in transition from said firstto said second conveyance means;

first fluid curtain means disposed transverse to said first directionand to direct fluid flow against said transfer plane from one sidethereof into said separation to fluid dynamically urge free end portionsof said spools into said separation; and,

second fluid curtain means disposed transverse to said first directionand to direct fluid flow against said transfer plane from the other sidethereof on the second conveyance means side of said separation to fluiddynamically urge remaining free end portions of said spools away fromsaid transfer plane and around said spools.

2. Apparatus as described by claim 1 wherein said second conveyancemeans comprises a plurality of transversely spaced conveyance belts andthe fluid flow of said second fluid curtain means is directed throughthe spaces between said conveyance belts against said transfer plane.

4. A process of rewinding loose end portions of loosely wound spools ofthin sheet material, said process comprising the steps of:

depositing said loosely wound spools on first planar conveyance meanswith the winding axes of said spools substantially transverse to theconveyance direction; directing a first fluid flow stream against theconveyance plane of said conveyance means to fluid dynamically press aloose end portion of a spool thereagainst; directing said loose endportion from said conveyance plane into a separation space between saidfirst conveyance means and a second planar conveyance means; andbridging said separation space by said spool to draw said loose endportion between the wound body of said spool and the conveyance plane ofsaid second conveyance means. 5. A process as described by claim 4further comprising the step of:

directing a second fluid flow stream against said secsaid spool.

1. Apparatus for rewinding loose end portions of loosely wound spools ofthin sheet material, said apparatus comprising: first and second planarconveyance means disposed end to end for conveying loosely wound spoolsof thin sheet material along a substantially continuous transfer planein a first direction, the winding axis of said spools beingsubstantially transverse to said first direction, said first and secondconveyance means being separated by a distance at least sufficient toreceive a single ply of said sheet material but to be bridged by saidspools in transition from said first to said second conveyance means;first fluid curtain means disposed transverse to said first directionand to direct fluid flow against said transfer plane from one sidethereof into said separation to fluid dynamically urge free end portionsof said spools into said separation; and, second fluid curtain meansdisposed transverse to said first direction and to direct fluid flowagainst said transfer plane from the other side thereof on the secondconveyance means side of said separation to fluid dynamically urgeremaining free end portions of said spools away from said transfer planeand around said spools.
 2. Apparatus as described by claim 1 whereinsaid second conveyance means comprises a plurality of transverselyspaced conveyance belts and the fluid flow of said second fluid curtainmeans is directed through the spaces between said conveyance beltsagainst said transfer plane.
 3. Apparatus as described by claim 2wherein said first and second fluid curtain means comprises elongatedfluid manifold means having fluid outlet means disposed along the lengththereof.
 4. A process of rewinding loose end portions of loosely woundspools of thin sheet material, said process comprising the steps of:depositing said loosely wound spools on first planar conveyance meanswith the winding axes of said spools substantially transverse to theconveyance direction; directing a first fluid flow stream against theconveyance plane of said conveyance means to fluid dynamically press aloose end portion of a spool thereagainst; directing said loose endportion from said conveyance plane into a separation space between saidfirst conveyance means and a second planar conveyance means; andbridging said separation space by said spool to draw said loose endportion between the wound body of said spool and the conveyance plane ofsaid second conveyance means.
 5. A process as described by claim 4further comprising the step of: directing a second fluid flow streamagainst said second conveyance plane to fluid dynamically lift a looseend portion of a spool away from said second conveyance plane and aroundthe wound body of said spool.